Crystalline forms of modafinil

ABSTRACT

The present invention provides an improved process for preparing modafinil, whereby it may be isolated in high purity by a single crystallization. The process produces modafinil free of sulphone products of over-oxidation and other byproducts. The invention further provides new crystalline Forms II-VI of modafinil and processes for preparing them. Each of the new forms is differentiated by a unique powder X-ray diffraction pattern. The invention further provides pharmaceutical compositions containing novel modafinil Forms II-IV and VI.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. provisional applications No.60/221,110, filed Jul. 27, 2000; No. 60/226,491, filed Aug. 18, 2000;No. 60/229,160, filed Aug. 30, 2000; No. 60/230,088, filed Sep. 5, 2000and 60/593,332, filed Jan. 2, 2001 which are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates to a process for preparing modafinil freeof impurities, as well as new crystalline forms of modafinil andprocesses for their preparation.

BACKGROUND OF THE INVENTION

(±) 2-[(Diphenylmethyl)sulfinyl]acetamide of formula 1, also known asmodafinil, exerts a wakefulness-promoting effect on humans and animals.

The psychotropic activity of modafinil was demonstrated in tests onanimals such as those described in U.S. Pat. No. 4,177,290 (“the '290patent”) and in clinical trials on human patients. Modafinil racemate isapproved by the F.D.A. for treatment of narcolepsy.

The '290 patent describes preparations of modafinil. In Example 1 of the'290 patent, modafinil is prepared by reacting2-[(diphenylmethyl)thio]acetic acid chloride with ammonia, isolating theproduct amide and then oxidizing its sulfide group with hydrogenperoxide in acetic acid. Example 1a of the '290 patent describes adifferent synthetic method for an industrial scale preparation ofmodafinil. Benzhydrol is reacted with thiourea to form an intermediatewhich is then hydrolyzed to 2-[(diphenylmethyl)thio]acetic acid. Theacid is then oxidized in situ with hydrogen peroxide in a mixturecontaining chloroacetic acid and water. The resulting sulfoxide is thentreated with dimethyl sulfate to methylate the carboxylic acid group.The resulting ester is derivatized with ammonia to modafinil.

Each of these methods uses hydrogen peroxide to oxidize a sulfide groupto a sulfoxide. Drabowicz, J et al. Synthesis, 1990, 37-38 describes aprocedure for oxidizing sterically hindered sulfides to sulfoxides. Theprocedure uses hydrogen peroxide as the oxidizing agent, methanol as thesolvent and a mixture of sulfuric acid and one of several branchedaliphatic alcohols as a catalyst. The procedure is well adapted foroxidizing sterically hindered sulfides. No products of over-oxidationwere observed by thin layer chromatography of the reaction mixtures. Useof this methodology to prepare modafinil has not been described in theliterature.

Sulfides also may be oxidized to sulfoxides with other oxidizing agents,such as sodium periodate, t-butyl hypochlorite, calcium hypochlorite,sodium chlorite, sodium hypochlorite, meta-chloroperbenzoic acid andsodium perborate. March J. Advanced Organic Chemistry 1201-02 (4th ed.1992).

We have discovered that the process of Example 1 of the '290 patentsuffers from a problem of over-oxidation of the sulfide to sulphone 2.

By comparing the above presented chemical structures it will be readilyappreciated that separation of the sulphone once formed from modafinilis a difficult task. Therefore, the development of selective oxidationmethods are required in order to obtain modafinil free of sulphone afterone or more recrystallizations.

In the process described in Example 1a, significant amounts ofintermediates 2-[(diphenylmethyl)sulfinyl]acetic acid 3 and methyl2-[(diphenylmethyl)sulfinyl]acetate 4 are obtained because of incompleteconversion of the starting materials in Steps (b) and (c). Becue, T;Broquaire, M. J. Chromatography 1991, 557, 489-494. These compounds arealso difficult to separate from modafinil.

Due to the volume of solvent used by industrial scale processes and theenvironmental issues raised by the disposal of large amounts of organicsolvent, an industrial preparation that yields modifinil essentiallyfree of impurities and requires only one crystallization of the endproduct to obtain modifinil free of impurities within the limit ofdetection is highly advantageous over an alternative process thatrequires repeated recrystallizations to obtain modifil in equivalentpurity. Although Example 1 a of the '290 patent is described as anindustrial process, two recrystallizations were used to obtain theproduct as a white crystalline powder. The composition of that powder isnot reported.

It would be highly desirable to have an improved process that producesmodafinil essentially free of sulphone 2 so that it may be obtained inhigh purity by a single crystallization. In addition, it also would behighly desirable to avoid using dimethyl sulfate, one of the reagents inExample 1a, since it is highly toxic.

While pursuing the object of efficiently producing modafinil in highpurity, we discovered that modafinil can be crystallized into severaldistinct solid state crystalline polymorphic forms. Crystalline forms ofa compound are differentiated by the positions of the atomic nuclei inthe unit cell of the solidified compound. The differences producedifferent macroscopic properties like thermal behavior, vaporpermeability and solubility, which have practical consequences inpharmacy. Crystalline forms of a compound are most readily distinguishedby X-ray analysis. Single crystal X-ray crystalography yields data thatcan be used to determine the positions of the nuclei which in turn maybe visualized with computer or mechanical models, thus providing athree-dimensional image of the compound. While single crystal X-raystudies provide unmatched structural information, they are expensive andquality data can sometimes be difficult to acquire. Powder X-raydiffraction spectroscopy is used more frequently by the pharmaceuticalindustry to characterize new crystalline forms of drugs than is singlecrystal X-ray analysis. Powder X-Ray diffraction spectroscopy yields afingerprint that is unique to the crystalline form and is abledistinguish it from the amorphous compound and all other crystallineforms of the compound.

There is a wide variety of techniques that have the potential ofproducing different crystalline forms of a compound. Examples includecrystallization, crystal digestion, sublimation and thermal treatment.In the laboratory preparation in Example 1 of the '290 patent, modafinilis first precipitated by adding water to a reaction mixture containingmodafinil, water and excess hydrogen peroxide. Modafinil is thenrecrystallized from methanol. In the industrial scale preparation ofExample 1a, modafinil is obtained as a white powder by firstcrystallizing from a 1:4 mixture of methanol and water and thencrystallizing again from a 1:9 methanol/water mixture. Crystallizationfrom methanol and a 1:9 methanol/water mixture produces modafinil inpolymorphic Form I. Modafinil Form I is characterized by a powder X-raydiffraction (“PXRD”) pattern (FIG. 1) with reflections at 9.0, 10.2,11.2, 12.9, 15.2, 15.8, 16.3, 17.7, 18.2, 19.3, 20.5, 21.6, 21.9, 23.2,26.6±0.2 degrees 2θ.

U.S. Pat. No. 4,927,855 describes the preparation of the levorotatoryenantiomer of modafinil by chiral resolution of the2-[(diphenylmethyl)sulfinyl]acetic acid with α-methylbenzyl amine. Afterrecovery and amidation of the enantiomerically pure acid, (−) modafinilwas obtained as white crystals by crystallization from ethanol.

The discovery of a new crystalline form of a pharmaceutically usefulcompound provides an opportunity to improve the performancecharacteristics of a pharmaceutical product. It enlarges the repertoireof materials that a formulation scientist has available for designing,for example, a pharmaceutical dosage form of a drug with a targetedrelease profile or other desired characteristic. It is clearlyadvantageous when this repertoire is enlarged by the discovery of newcrystalline forms of a useful compound. Five new crystalline forms ofmodafinil that are not accessible by following crystallizationprocedures previously described in the art have now been discovered.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 represents an powder X-ray diffraction pattern of Modafinil FormI.

FIG. 2 represents an powder X-ray diffraction pattern of Modafinil FormII.

FIG. 3 represents an powder X-ray diffraction pattern of Modafinil FormIII.

FIG. 4 represents an powder X-ray diffraction pattern of Modafinil FormIV.

FIG. 5 represents an powder X-ray diffraction pattern of Modafinil FormV.

FIG. 6 represents an powder X-ray diffraction pattern of Modafinil FormVI.

SUMMARY OF THE INVENTION

The present invention provides a process for preparing modafinil,whereby it may be isolated in high purity by a single crystallization.The process includes oxidation of 2-[(diphenylmethyl)thio]acetamide withH₂O₂ in a mixture of a mineral acid, an alcohol or phase transfercatalyst and optionally an inert liquid organic medium. Modafinil isprecipitated from the reaction mixture and then crystallized in ≧99.5%purity. The oxidation method produces modafinil essentially free ofsulphone products of over-oxidation which enables modafinil to beobtained free of sulphone within the limits of UV detection after twocrystallizations.

The present invention further provides new crystalline Forms II-VI ofmodafinil and processes for preparing them. Each of the new forms isdifferentiated by a unique powder X-ray diffraction pattern.

The present invention further provides pharmaceutical compositionscontaining novel modafinil Forms II-IV and VI.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In this disclosure, modafinil with a combined impurity content of lessthan 0.1% is referred to as “highly pure” modafinil. Purity is measuredby UV absorbance at λ=225 nm. Compounds containing phenyl rings absorbstrongly in this region of the U.V. spectrum. Modafinil and problematicimpurities 2-4 each possess two phenyl UV chromophores. Modafinil thatcontains less than 0.01% of an impurity such as sulphone 2 is referredto as “essentially free” of that impurity and modafinil that is free ofan impurity within the limit of detection of the purity analysis or thatcontains less than 0.0001% of the impurity is referred to as being“free” of that impurity.

The present invention provides an improved synthetic preparation ofmodafinil whereby modafinil may be isolated in ≧99.5% purity after asingle recrystallization, preferably ≧99.9% purity. In this improvedprocess, 2-[(diphenylmethyl)thio]acetamide is oxidized to modafinil. Themodafinil is then separated as a solid from the reagents used in theoxidation and thereafter is isolated in high purity by a singlerecrystallization.

In the oxidation step, hydrogen peroxide is reacted with2-[(diphenylmethyl)thio] acetamide in the presence of a mineral acid anda linear, branched or cyclic alcohol, or a phase transfer catalyst,optionally in an inert liquid organic medium. The oxidizing conditionsare discussed generally in Drabowicz, J et al. Synthesis, 1990, 37-38.U.S. Pat. No. 4,177,290 is incorporated by reference for its teaching ofa preparation of 2-[(diphenylmethyl)thio] acetamide.

Hydrogen peroxide is preferably supplied as a 10-50 wt. % solution inwater, more preferably about 30-33 wt. % solution in water. Suchsolutions are commercially available (e.g. 1998-99 Aldrich Chemical Co.Cat. Nos. 42,065-4; 42,066-2; 31,698-9; 21,676-3).

Exemplary mineral acids that may be used include H₂SO₄, HlO₄ and H₃PO₄.

Preferred alcohols are derived from hydrocarbons with seven or fewercarbon atoms and that are unsubstituted except for the hydroxyl group.Branched alcohols are most preferred. Isopropyl alcohol, tert-butanoland 2-methyl-1-butanol are exemplary of alcohols that may be used.Suitable phase transfer catalysts include triethylbenzylammoniumchloride (TEBA) and polyethylene glycol.

An inert liquid organic medium is a diluent for the oxidation reactionthat may decrease the rate of the oxidation but does not preventoxidation of the sulfide group of 2-[(diphenylmethyl)thio]acetamide to asulfoxide group or cause overoxidation of the sulfide group to asulphone. Preferred inert liquid organic media are unbranched alcoholssuch as methanol, ethanol and ethylene glycol; ketones, such as acetone,which may contain water; esters, such as ethyl acetate anddimethylcarbonate; and mixtures thereof.

In the oxidation step, 2-[(diphenylmethyl)thio]acetamide (“the sulfide”)is contacted with an excess of hydrogen peroxide, preferably from about1.5 to about 4 molar equivalents. The mineral acid need only be used ina catalytic amount, preferably from about 0.02 to about 0.2 molarequivalents with respect to the sulfide. The alcohol or phase transfercatalyst is preferably used in an amount of from about 2 to about 4equivalents with respect to the sulfide, more preferably about 3equivalents. When an inert liquid organic medium is used, the oxidationreaction is preferably conducted at a sulfide concentration of fromabout 0.07 to about 0.2 grams of sulfide per milliliter of inert liquidorganic medium.

The required reagents may be added in any order desired and the reactionmixture may be maintained at any condition that causes oxidation of2-[(diphenylmethyl) thio]acetamide to modafinil. The following procedurehas been found in practice to produce modafinil in a sufficiently highstate of purity directly by precipitation from the reaction mixture thatmodafinil may be therafter obtained in ≧99.5% purity, more preferrablygreater than 99.9% purity, by a single crystallization.2-[(Diphenylmethyl)thio]acetamide is suspended in the inert liquidorganic medium. The mineral acid and the alcohol or phase transfercatalyst are then added at room temperature. Hydrogen peroxide is thenadded. The temperature of the reaction mixture is raised to about 30° C.and stirred for several hours. Progress of the reaction may be monitoredby HPLC. After oxidation is complete, the reaction mixture is cooled toroom temperature and the excess hydrogen peroxide is decomposed with,for example, sodium metabisulfite, sodium thiosulfide, sodium sulfide orferrous sulfate.

After the oxidation is complete and any excess H₂O₂ has been decomposed,modafinil is precipitated from the reaction mixture. Precipitation canbe accelerated by adding water. Modafinil is then separated from thereaction mixture by conventional means such as filtering or decanting.The modafinil preferably is then washed with an organic solvent andwater.

The improved process for preparing modafinil produces modafinil with alow content of 2-[(diphenylmethyl)sulfonyl]acetamide 2, 2-[(diphenylmethyl)sulphinyl] acetic acid 3, and methyl2-[(diphenylmethyl)sulphinyl] acetate 4, which can be removed with asingle recrystallization. The modafinil that precipitates from thereaction mixture should be 98-99% pure or greater and will typicallycontain less than 0.1% suphone 2. Modafinil has been precipitateddirectly from the reaction mixture with less than 0.01% contaminationwith sulphone 2. The composition of the oxidation reaction mixture maybe monitored quantitatively by HPLC to confirm that the reaction isproceeding cleanly. A reverse phase HPLC method with UV detection atλ=225 nm may be used.

Although modafinil obtained by oxidation according to theabove-described process may be recrystallized from a variety of solventsin high purity, the best recrystallization solvents have been found tobe methanol, ethanol, dimethylcarbonate, acetone, and mixtures thereof.The best multicomponent solvent systems are ethanol/dimethylcarbonate,acetone/dimethylcarbonate, acetone/water, acetone/ethyl acetate,acetone/dimethylcarbonate/water and methanol/dimethylcarbonate. Anespecially preferred recrystallization solvent is dimethyl carbonate.

The modafinil that is obtained after crystallization is ≧99.5%, pure,more preferably ≧99.9% pure and contains less than 0.02%, morepreferably less than 0.01% of of sulphone 2. After crystallization frompreferred recrystallization solvents, modafinil may be obtained free ofsulphone 2, i.e. with no more than 0.0002% or 0.0001% contamination. Itwill be appreciated that such minute quantities of impurity are at orbeyond the limits of detection of many analytical techniques.

In a second aspect, the present invention provides novel crystallinemodafinil Forms II-VI and processes for their preparation.

A general technique that leads to the discovery of a novel crystallineform of a compound may be well known to those skilled in the art. Infact, that is commonly the case. Such techniques includecrystallization, crystal digestion, sublimation, thermal treatment, andpH adjustment. Those skilled in the art will appreciate that in thesearch for new polymorphic forms of a compound, any one of thesetechniques is expected to fail to produce a new crystalline form of thecompound. The search is an empirical exercise that involves trial anderror experimentation with different techniques and conditions. Forthese reasons, it is not possible to define all techniques andconditions that will produce modafinil crystalline Forms II-VI. It is,however, possible to provide methods which have successfully andselectively produced modafinil in one of these desired forms.

The novel crystalline forms of modafinil have been characterized bypowder X-ray diffraction spectroscopy which produces a fingerprint ofthe particular crystalline form. Measurements of 2θ values typically areaccurate to within ±0.2 degrees.

X-ray diffraction data were acquired using a Philips powder X-raydiffractometer, Goniometer model 1050/70 at a scanning speed of 2° perminute, with a CU_(Kα) radiation of λ=1.5418 Å. The sample was gentlyground and dusted over a zero background quartz plate to give a thinlayer.

Modafinil Form I

The present invention provides processes for preparing modafinil Form I.

Modafinil Form I may prepared by crystallization from acetone,acetonitrile, benzyl alcohol, dimethyl formamide, methanol, methyl ethylketone or 2-pyrrolidone. Preferred recrystallization solvents aremethanol and acetone. Crystallization may be accelerated by cooling thesolution, adding an antisolvent or seeding the solution with a crystalof modafinil Form I. Preferred solvent/anti-solvent combinations areacetone/water, DMF/water, acetonitrile/water, ethanol/water andmethanol/ethyl acetate.

Modafinil Form I also may be prepared by suspending a mixture ofmodafinil Forms I and II in ethyl acetate for a sufficient time tocomplete the conversion. If the starting modafinil form is Form II, thenseveral other organic liquids may be substituted for ethyl acetate topromote conversion to Form I. In particular, Form II modafinil also maybe converted into Form I modafinil by suspending it in methyl tert-butylether (“MTBE”), water or isobutyl acetate. It is particularly convenientto practice this technique for preparing Form I by simply slurryingmodafinil (in any other form) with ethyl acetate, isobutyl acetate orwater until the conversion is complete.

Forms V and VI convert into modafinil Form I upon gentle heating toabout 80° C. or above. Forms V and VI may be transformed into Form Iwithout significant decomposition by heating to about 100° C.

Modafinil Form I may be separated from solvents conventionally byfiltering or decanting and then drying. Form I has been dried at atemperature as high as 100° C. without converting to another crystallineor amorphous form and without undergoing significant chemicaldecomposition.

Modafinil Form II

The present invention also provides modafinil Form II. Modafinil Form IIproduces a powder X-ray diffraction pattern (FIG. 2) with reflections at9.1, 10.3, 11.1, 11.9, 14.3, 15.2, 16.4, 17.5, 18.4, 20.5, 21.3, 24.6,26.6±0.2 degrees 2θ. The strong reflections at 14.3, 17.5, 20.5 and 21.3degrees 2θ are particularly characteristic. Of these, the reflections at14.3, 17.5 and 21.3 degrees 2θ are most characteristic.

The following techniques have proven effective for producing modafinilin crystalline Form II.

Modafinil Form III converts into modafinil Form II when it is suspendedin water. Thus, suspending Form III in water provides a method ofaccessing modafinil Form II.

Modafinil also crystallizes selectively in Form II from ethanol,isopropanol, n-butanol, t-butanol, methyl isobutyl ketone, ethyleneglycol, dioxolane and dioxane by heating to dissolve modafinil in thesolvent and cooling to recrystallize. Modafinil Form II also may beprepared by reslurrying in dichloroethane and by rapidly cooling asolution of modafinil in a methanol and water mixture.

Modafinil Form III

The present invention also provides modafinil Form III. Modafinil FormIII produces a powder X-ray diffraction pattern (FIG. 3) withreflections at 7.4, 9.0, 10.5, 12.3, 14.2, 14.7, 15.1, 16.4, 18.3, 20.0,20.5, 21.1, 22.1, 24.5±0.2 degrees 2θ. The strong reflections at 7.4,10.5, 18.3, 20.0 and 20.5 degrees 2θ are particularly characteristic. Ofthese, the reflections at 7.4, 10.5, 18.3 and 20.0 degrees 2θ arecharacteristic for their intensity and the absence of reflections atcorresponding positions in the PXRD patterns of the other forms.

Modafinil Form III is produced by crystallization from toluene. Form IIIhas also been crystallized from mixtures of dimethyl carbonate andethanol, although it has in instances been obtained in mixture with FormV when crystallized from this mixed solvent system.

Modafinil Form IV

The present invention also provides modafinil Form IV. Modafinil Form IVproduces a powder X-ray diffraction pattern (FIG. 4) with reflections at6.9, 10.4, 14.1, 17.2, 18.5, 20.3, 20.8, 21.6, 22.7, 25.0, 26.5, 27.6,28.5±0.2 degrees 2θ. The strong reflections at 6.9, 10.4, 17.2, 20.3 and22.7 degrees 2θ are particularly characteristic.

Modafinil crystallizes from tetrahydrofuran and dimethyl sulfoxide incrystalline Form IV.

Modafinil Form V

The present invention also provides modafinil Form V. Form V produces apowder X-ray diffraction pattern (FIG. 5) with reflections at 7.4, 9.3,10.5, 12.4, 14.7, 16.2, 18.2, 19.9, 21.5, 22.0, 23.6, 24.5, 25.2, 28.4,29.5, 31.8±0.2 degrees 2θ. The strong reflections at 9.3, 12.4, 18.2,19.9, and 22.0 degrees 2θ are particularly characteristic.

Form V is prepared by crystallization from dimethylcarbonate andmixtures of dimethylcarbonate and ethanol, dimethylcarbonate and waterand dimethylcarbonate and acetone.

Thermogravimetric analysis of Form V showed a mass loss of about 12%starting at about 100° C. up to 150° C. This LOD is consistent with FormV being a hemi-solvate of modafinil with dimethylcarbonate. The TGAanalysis was performed on a Shimadzu DTG 60, with a sample of about 10mg that was heated at the rate of about 10° C. per min from aboutambient temperature to about 300° C.

Modafinil Form VI

The present invention also provides modafinil Form VI. Form VI producesa powder X-ray diffraction pattern (FIG. 6) with reflections at 9.0,9.3, 10.2, 12.4, 14.2, 14.5, 15.3, 17.5, 18.1, 20.0, 20.5, 21.5, 22.0,23.5, 24.5, 25.0±0.2 degrees 2θ. The reflections at 9.3, 18.1, and 20.5degrees 2θ are particularly characteristic for their intensity.

Modafinil Form VI may be prepared by suspending modafinil Form V inwater, ethanol or a water/ethanol mixture for a sufficient time tocomplete the conversion. Preferably, modafinil Form VI is slurried inwater, ethanol, or an ethanol/water mixture at about 28° C., followed bydrying under vacuum at 55° C.

Amorphous Modafinil

Modafinil may be prepared in an amorphous state by crystallization frommixtures of ortho, meta orpara xylene.

Having described techniques best suited for producing distinctcrystalline Forms II-VI of modafinil in a laboratory and industrialsetting, those skilled in the art will appreciate that these forms maybe accessible by yet other methods.

Pharamaceutical Compositions Containing Modafinil Forms II-IV and VI

Modafinil Forms II-IV and VI may be formulated into a variety ofpharmaceutical compositions and dosage forms that are useful forpromoting wakefulness in patients afflicted with narcopolepsy.

Pharmaceutical compositions of the present invention contain modafinilForms II-IV and VI, optionally in mixture with each other.Pharmaceutical compositions of the present invention also may containother modafinil crystalline forms, amorphous modafinil and/or otheractive ingredients in mixture with one or more of modafinil Forms II-IVand VI. In addition to the active ingredient(s), modafinilpharmaceutical compositions of the present invention may contain one ormore excipients. Excipients are added to the composition for a varietyof purposes.

Diluents increase the bulk of a solid pharmaceutical composition and maymake a pharmaceutical dosage form containing the composition easier forthe patient and caregiver to handle. Diluents for solid compositionsinclude, for example, microcrystalline cellulose (e.g. Avicel®),microfine cellulose, lactose, starch, pregelitinized starch, calciumcarbonate, calcium sulfate, sugar, dextrates, dextrin, dextrose, dibasiccalcium phosphate dihydrate, tribasic calcium phosphate, kaolin,magnesium carbonate, magnesium oxide, maltodextrin, mannitol,polymethacrylates (e.g. Eudragit®), potassium chloride, powderedcellulose, sodium chloride, sorbitol and talc.

Solid pharmaceutical compositions that are compacted into a dosage formlike a tablet may include excipients whose functions include helping tobind the active ingredient and other excipients together aftercompression. Binders for solid pharmaceutical compositions includeacacia, alginic acid, carbomer (e.g. carbopol), carboxymethylcellulosesodium, dextrin, ethyl cellulose, gelatin, guar gum, hydrogenatedvegetable oil, hydroxyethyl cellulose, hydroxypropyl cellulose (e.g.Klucel®), hydroxypropyl methyl cellulose (e.g. Methocel®), liquidglucose, magnesium aluminum silicate, maltodextrin, methylcellulose,polymethacrylates, povidone (e.g. Kollidon®, Plasdone®), pregelatinizedstarch, sodium alginate and starch.

The dissolution rate of a compacted solid pharmaceutical composition inthe patient's stomach may be increased by the addition of a disintegrantto the composition. Disintegrants include alginic acid,carboxymethylcellulose calcium, carboxymethylcellulose sodium (e.g.Ac-Di-Sol®, Primellose®), colloidal silicon dioxide, croscarmellosesodium, crospovidone (e.g. Kollidon®, Polyplasdone®), guar gum,magnesium aluminum silicate, methyl cellulose, microcrystallinecellulose, polacrilin potassium, powdered cellulose, pregelatinizedstarch, sodium alginate, sodium starch glycolate (e.g. Explotab®) andstarch.

Glidants can be added to improve the flow properties of non-compactedsolid compositions and improve the accuracy of dosing. Excipients thatmay function as glidants include colloidal silicon dixoide, magnesiumtrisilicate, powdered cellulose, starch, talc and tribasic calciumphosphate.

When a dosage form such as a tablet is made by compaction of a powderedcomposition, the composition is subjected to pressure from a punch anddye. Some excipients and active ingredients have a tendancy to adhere tothe surfaces of the punch and dye, which can cause the product to havepitting and other surface irregularities. A lubricant can be added tothe composition to reduce adhesion and ease release of the product fromthe dye. Lubricants include magnesium stearate, calcium stearate,glyceryl monostearate, glyceryl palmitostearate, hydrogenated castoroil, hydrogenated vegetable oil, mineral oil, polyethylene glycol,sodium benzoate, sodium lauryl sulfate, sodium stearyl fumarate, stearicacid, talc and zinc stearate.

Flavoring agents and flavor enhancers make the dosage form morepalatable to the patient. Common flavoring agents and flavor enhancersfor pharmaceutical products that may be included in the composition ofthe present invention include maltol, vanillin, ethyl vanillin, menthol,citric acid, fumaric acid ethyl maltol, and tartaric acid.

Compositions may also be colored using any pharmaceutically acceptablecolorant to improve their appearance and/or facilitate patientidentification of the product and unit dosage level.

Selection of excipients and the amounts to use may be readily determinedby the formulation scientist based upon experience and consideration ofstandard procedures and reference works in the field.

The solid compositions of the present invention include powders,granulates, aggregates and compacted compositions. The dosages includedosages suitable for oral, buccal, rectal, parenteral (includingsubcutaneous, intramuscular, and intravenous), inhalant and ophthalmicadministration. Although the most suitable route in any given case willdepend on the nature and severity of the condition being treated, themost preferred route of the present invention is oral. The dosages maybe conveniently presented in unit dosage form and prepared by any of themethods well-known in the pharmaceutical arts.

Dosage forms include solid dosage forms like tablets, powders, capsules,suppositories, sachets, troches and losenges as well as liquid syrups,suspensions and elixirs. An especially preferred dosage form of thepresent invention is a tablet.

Tablets, capsules, lozenges and other unit dosage forms preferablycontain modafinil in a dosage level of from about 50 to about 300 mg,more preferably from about 100 mg to about 200 mg.

Having described the invention with reference to certain preferredembodiments, the following examples are provided for the purpose ofillustrating, but not limiting, the invention.

EXAMPLES Examples 1-8 Preparations of Highly Pure Modafinil Example 1

In a three necked round bottom flask equipped with reflux condenser, athermometer and an agitator, diphenylmethylthio-2-acetamide (50 g) wassuspended in methanol (550 ml). A solution (44 ml) containing 1.2 mlH₂SO₄ dissolved in 46.7 ml isopropanol was added. A 30% solution of H₂O₂(45 ml) was added, causing the temperature to rise to 30° C. Thetemperature was maintained at 30° C. for 3.5 h. The reaction mass wascooled to 25° C. and diluted with 450 ml of water. The excess ofunreacted H₂O₂ was neutralized with Na₂S₂O₅ and additional 50 ml ofwater was added modafinil was separated by filtration and reslurriedwith 210 ml water. After drying 40.2 g modafinil was obtained (yield:75.7%).

Example 2

In a three necked round bottom flask equipped with a reflux condenser, athermometer and an agitator, diphenylmethylthio-2-acetamide (50 g) wassuspended in dimethylcarbonate (550 ml). A solution (44 ml) containing1.2 ml H₂SO₄ dissolved in 46.7 ml isopropanol was added. A 15% solutionof H₂O₂ (85 ml) was added, causing the temperature to rise to 30° C. Thetemperature was maintained at 30° C. for 30 h. The reaction mass wascooled to 25° C. and diluted with 450 ml of water. The excess ofunreacted H₂O₂ was neutralized with Na₂S₂O₅ and additional 50 ml ofwater was added modafinil was separated by filtration and reslurriedwith 210 ml water. After drying 45.1 g modafinil was obtained (yield85%).

Example 3

In a three necked round bottom flask equipped with reflux condenser, athermometer, and an agitator, 3 g of modafinil prepared as in Example 1was suspended in 32 ml acetone containing 5% water. The mixture washeated to reflux (˜58° C.) under a nitrogen atmosphere. The solution soobtained was cooled to 42° C. at which temperature crystallizationstarts. The suspension was further cooled to 25° C. and filtered. Afterdrying, 1.95 g of highly purified modafinil essentially free of sulphonewas obtained (yield: 65%).

Example 4

In a three necked round bottom flask equipped with reflux condenser, athermometer, and an agitator, 1 g of modafinil prepared as in Example 2was suspended in 10.5 ml ethanol. The mixture was heated to reflux undernitrogen. The suspension was cooled to 25° C. and filtered. After drying0.83 g of highly purified modafinil was obtained (yield: 83%).

Example 5

In a three necked round bottom flask equipped with reflux condenser, athermometer and an agitator, diphenylmethylthio-2-acetamide (50 g) wassuspended in dimethylcarbonate (550 ml). A solution (44 ml) containing1.2 ml H₂SO₄ dissolved in 46.7 ml isopropanol was added. Further 49 mlof 30% H₂O₂ was added. The temperature increases to 30° C. and wasmaintained constant during 8 h. The reaction mass was cooled to 25° C.and diluted with 450 ml of water. The excess of unreacted H₂O₂ wasneutralized with Na₂S₂O₅ and additional 50 ml of water was added.Modafinil was separated by filtration and reslurried with 210 ml water.After drying 45.1 g modafinil was obtained (yield 85%).

Example 6

In a three necked round bottom flask equipped with reflux condenser, athermometer, and an agitator, 3 g of modafinil prepared as in Example 5was suspended in a mixture containing 100 ml acetone and 20 mldimethylcarbonate. Under nitrogen, the mixture was heated to reflux(˜58° C.). The solution so obtained was cooled to 47° C. at whichtemperature crystallization starts. The suspension was further cooled to25° C. and filtered. After drying 2.52 g of highly purified modafinilessentially free of sulphone was obtained (yield: 84%).

Example 7

In a three necked round bottom flask equipped with reflux condenser, athermometer, and an agitator, 3.7 g of undried modafinil obtained inExample 6 was suspended in a mixture containing 123.5 ml acetone and24.7 ml dimethylcarbonate. Under nitrogen the mixture was heated toreflux (˜58° C.). The obtained solution was cooled to 25° C. andfiltered. The filter cake was dried and again suspended in a mixture of94.5 ml acetone and 19 ml dimethylcarbonate and under nitrogen heated toreflux. The solution so obtained was cooled to 25° C. and filtered.After drying 2.32 g of highly purified modafinil free of sulphone wasobtained (yield: 62.7%).

Example 8

In a three necked round bottom flask equipped with reflux condenser, athermometer, and an agitator, 3 g of modafinil prepared as in Example 5was suspended in a mixture containing 1 ml acetone and 20 mldimethylcarbonate. Under nitrogen, the mixture was heated to reflux(˜58° C.). The obtained solution was cooled to 25° C. and filtered. Thewet filter cake was again suspended in a mixture of 100 ml acetone and0.20 ml dimethylcarbonate and under nitrogen heated to reflux. Thesolution so obtained was cooled to 25° C. and filtered. After drying,2.1 g of highly purified modafinil free of sulphone was obtained (yield:70.5%).

Examples 9-13 Preparations of Modafinil Form I Example 9

By Suspending Modafinil Form IV in Water. Modafinil Form IV (0.4 g) wassuspended in distilled water (50 ml) with a pH of about 5.9. Thesuspension was stirred for about 24 hours at about 37° C. and thenfiltered. The filtrate was analyzed by x-ray powder diffraction and wasdetermined to be modafinil Form I.

Example 10

By Heating Modafinil Forms V or VI A small aliquot of Modafinil Forms Vand VI are heated separately, for about 30 minutes, in an oven at about100° C. Modafinil Forms V and VI were subsequently analyzed by x-raypowder diffraction and both were determined to be Form I.

Example 11

Crystallization from Acetonitrile. Modafinil (3 g) was suspended inacetonitrile (23 ml) in a three-necked round bottom flask equipped witha reflux condenser, a thermometer, and an agitator. The mixture washeated to reflux (about 80° C.). The resulting solution was cooled toabout 63° C. at which point crystallization began. The suspension wasfurthered cooled to about 25° C. and then filtered. After drying,crystallized modafinil (1.96 g) Form I was obtained (65% yield).

Example 12

Crystallization from Dimethylformamide. Modafinil (3 g) was suspended indimethylformamide (5.5 ml) in a three-necked round bottom flask equippedwith a reflux condenser, a thermometer, and an agitator. The mixture washeated to reflux (about 60° C.). A clear solution was obtained. Water (5ml) was added dropwise to the solution which caused modafinil to beginprecipitating. Precipitation was completed by cooling the mixture toabout 25° C. The product was separated by filtration. After drying,crystallized modafinil (2.54 g) Form I was obtained (84.7% yield).

Example 13

Crystallization from Ethyl Acetate. Modafinil (3 g) was suspended inethyl acetate (50 ml) in a three-necked round bottom flask equipped witha reflux condenser, a thermometer, and an agitator. The mixture washeated to reflux (about 77° C.) and maintained for about 1 hour. Themixture was cooled to about 25° C. and then was filtered. After drying,crystallized modafinil Form 1 (1.9 g) was obtained (63% yield).

EXAMPLES 14-15 Preparation of Modafinil Form II Example 14

Crystallization from Isopropanol. Modafinil (3 g) was suspended inisopropanol (34 ml) in a three-necked round bottom flask equipped with areflux condenser, a thermometer, and an agitator. The mixture was heatedto reflux (about 85° C). The resulting solution was cooled to about 58°C. at which point crystallization began. The suspension was cooled toabout 25° C. and then was filtered. After drying, crystallized modafinilForm II (2.32 g) was obtained (77.3% yield).

Example 15

From a Suspension of Modafinil Form III in Water: Modafinil Form III(0.4 g) was suspended in distilled water (50 ml) having a pH of about5.9. The suspension was stirred for about 24 hours at about 37° C. andthen was filtered. The filtrate was analyzed by powder X-ray diffractionand was determined to be modafinal Form II.

Example 16 Preparation of Modafinil Form III Example 16

Crystallization from Toluene. Modafinil (3 g) was suspended in oftoluene (90 ml) in a three-necked round bottom flask equipped with areflux condenser, a thermometer, and an agitator. The mixture was heatedto reflux (about 110° C.). The resulting solution was cooled to about35° C. at which point crystallization began. The suspension wasmaintained for about 17 hours at about 25° C., cooled to about 5° C.,and then was filtered. After drying, crystallized modafinil (0.6 g) FormIII was obtained (19.6% yield).

Example 17 Preparation of Modafinil Form IV Example 17

Crystallization from Tetrahydrofuran. Modafinil (3 g) was suspended intetrahydrofuran (90 ml) in a three-necked round bottom flask equippedwith a reflux condenser, a thermometer, and an agitator. The mixture isheated to reflux (about 63° C.). The resulting solution was cooled toabout 53° C. at which point crystallization began. The suspension wascooled to about 25° C. and then was filtered. After drying, crystallized(2.4 g) modafinil Form IV was obtained (80% yield).

Example 18 Preparation of Modafinil Form V Example 18

Crystallization from Dimethylcarbonate. Modafinil (3 g) was suspended indimethylcarbonate (105 ml). The mixture was heated to reflux (about 90°C.) in a three-necked round bottom flask equipped with a refluxcondenser, a thermometer, and an agitator. After about 2 hours atreflux, the resulting solution was cooled to about 79° C. at which pointcrystallization began. The suspension was cooled to about 25° C. andthen was filtered. After drying, about crystallized modafinil (3 g) FormV was obtained (about 90% yield).

Example 19 Preparation of Modafinil Form VI Example 19

From a Suspension of Form V in Ethanol. Modafinil (3.5 g) Form V wassuspended in ethanol (10 ml) in a three-necked round bottom flaskequipped with a descending condenser, a thermometer, and an agitator.The mixture was stirred for about 4.5 hours at about 25° C. and then wasfiltered. After drying, crystallized modafinil (2.9 g) Form VI wasobtained (82% yield).

Example 20 Preparation of Amorphous Modafinil Example 20

Crystallization from Xylenes. Modafinil (5 g) was suspended in of xylene(150 ml) in a three-necked round bottom flask equipped with a descendingcondenser, a thermometer and an agitator. The mixture was heated toabout 110° C., which was maintained for about 30 minutes. The resultingsolution was cooled to about 35° C. at which point crystallizationbegan. The suspension was maintained for about 17 hours at about 25° C.,then cooled to about 5° C., and then was filtered. After drying,amorphous modafinil (1.83 g) was obtained (36.6% yield).

Having thus described the invention with reference to certain preferredembodiments, other embodiments will become apparent to one skilled inthe art from consideration of the specification and examples. It isintended that the specification, including the examples, is exemplaryonly, with the scope and spirit of the invention being defined by theclaims which follow.

1-20. (canceled)
 21. A process for preparing modafinil Form I comprisingthe steps of: a) dissolving modafinil in a liquid selected from thegroup consisting of acetone, acetonitrile, benzyl alcohol, dimethylformamide, methanol, methyl ethyl ketone, pyrrolidone and mixturesthereof, b) crystallizing modafinil from the liquid, and c) separatingthe liquid to obtain modafinil Form I.
 22. The process of claim 21wherein the liquid is methanol or acetone.
 23. A process for preparingmodafinil Form I comprising the steps of: a) suspending modafinil inethyl acetate for a period of time sufficient to convert it intomodafinil Form I, and b) separating the ethyl acetate to obtainmodafinil Form I.
 24. A process for preparing modafinil Form Icomprising the steps of: a) suspending crystalline Form II modafinil ina liquid selected from the group consisting of methyl t-butyl ether,water, isobutyl acetate and mixtures thereof for a period of timesufficient to convert the Form II modafinil into modafinil Form I, andb) separating the liquid to obtain modafinil Form I.
 25. A process forpreparing modafinil Form I by heating Form V modafinil to about 80° C.or higher temperature for a period of time sufficient to convert theForm V modafinil into Form I modafinil.
 26. A process for preparingmodafinil Form I by heating Form VI modafinil to about 80° C. or highertemperature for a period of time sufficient to convert the Form Vmodafinil into modafinil Form I.
 27. A crystalline form of modafinilthat produces a powder X-ray diffraction pattern with reflections at14.3, 17.5, 20.5 and 21.3±0.2 degrees 2θ.
 28. The crystalline modafinilof claim 27 denominated modafinil Form II.
 29. The crystalline form ofmodafinil of claim 27 wherein the reflections at 14.3, 17.5, 20.5 and21.3±0.2 degrees 2θ comprise a first set of reflections of strongintensity and wherein the crystalline form is further characterized byreflections of lesser intensity at 9.1, 10.3, 11.9, 15.2, 18.4, 24.6 and26.6±0.2 degrees 2θ.
 30. The crystalline form of modafinil of claim 27that produces a powder X-ray diffraction pattern with reflections at9.1, 10.3, 11.1, 11.9, 14.3, 15.2, 16.4, 17.5, 18.4, 20.5, 21.3, 24.6,26.6±0.2 degrees 2θ.
 31. A process for preparing the modafinil of claim27 comprising the steps of: a) suspending Form III modafinil in waterfor a period of time sufficient to convert Form III modafinil into themodafinil of claim 27, and b) separating the water to obtain themodafinil of claim
 27. 32. A process for preparing the modafinil ofclaim 27 comprising the steps of: a) dissolving modafinil in a liquidselected from the group consisting of ethanol, isopropanol, n-butanol,t-butanol, methyl isobutyl ketone, ethylene glycol, dioxolane, dioxaneand mixtures thereof, b) crystallizing modafinil from the liquid, and c)separating the liquid to obtain the modafinil of claim
 27. 33. Acrystalline form of modafinil that produces a powder X-ray diffractionpattern with reflections at 7.4, 10.5, 20.0 and 20.5±0.2 degrees 2θ. 34.The crystalline modafinil of claim 33 denominated modafinil Form III.35. The crystalline form of modafinil of claim 33 wherein thereflections at 7.4, 10.5, 20.0 and 20.5±0.2 degrees 2θ comprise a firstset of reflections of strong intensity and wherein the crystalline formis further characterized by reflections of lesser intensity at 9.0,12.3, 22.1 and 24.5±0.2 degrees 2θ.
 36. The crystalline form ofmodafinil of claim 35 that produces a powder X-ray diffraction patternwith reflections at 7.4, 9.0, 10.5, 12.3, 14.2, 14.7, 15.1, 16.4, 18.3,20.0, 20.5, 21.1, 22.1, 24.5±0.2 degrees 2θ.
 37. A process for preparingthe modafinil of claim 33 comprising the steps of: a) dissolvingmodafinil in a liquid selected from the group consisting of toluene andmixtures of ethanol and dimethylcarbonate, b) crystallizing modafinilfrom the liquid, and c) separating the liquid to obtain the modafinil ofclaim
 33. 38. A crystalline form of modafinil that produces a powderX-ray diffraction pattern with reflections at 6.9, 10.4, 17.2, 20.3 and22.7±0.2 degrees 2θ.
 39. The crystalline modafinil of claim 38denominated modafinil Form IV.
 40. The crystalline form of modafinil ofclaim 38 wherein the reflections at 6.9, 10.4, 17.2, 20.3 and 22.7±0.2degrees 2θ comprise a first set of reflections of strong intensity andwherein the crystalline form is further characterized by reflections oflesser intensity at 14.1, 18.5, 20.8, 21.6 and 25.0±0.2 degrees 2θ. 41.The crystalline form of modafinil of claim 40 that produces a powderX-ray diffraction pattern with reflections at 6.9, 10.4, 14.1, 17.2,18.5, 20.3, 20.8, 21.6, 22.7, 25.0, 26.5, 27.6, 28.5±0.2 degrees 2θ. 42.A process for preparing the modafinil of claim 38 comprising the stepsof: a) dissolving modafinil in a liquid selected from the groupconsisting of tetrahydrofuran and dimethyl sulfoxide b) crystallizingmodafinil from the liquid, and c) separating the liquid to obtain themodafinil of claim
 38. 43. A crystalline hemisolvate of modafinil anddimethylcarbonate.
 44. The crystalline hemisolvate of modafinil anddimethylcarbonate of claim 43 that produces a powder X-ray diffractionpattern with reflections at 9.3, 12.4, 18.2, 19.9 and 22.0±0.2 degrees2θ.
 45. The crystalline hemisolvate of modafinil and dimethylcarbonateof claim 43 denominated modafinil Form V.
 46. The crystalline form ofmodafinil of claim 44 wherein the reflections at 9.3, 12.4, 18.2, 19.9and 22.0±0.2 degrees 2θ comprise a first set of reflections of strongintensity and wherein the crystalline form is further characterized byreflections of lesser intensity at 7.4, 24.7, 26.2, 21.5, 23.6, 24.5 and25.2±0.2 degrees 2θ.
 47. The crystalline form of modafinil of claim 46that produces a powder X-ray diffraction pattern with reflections at7.4, 9.3, 10.5, 12.4, 14.7, 16.2, 18.2, 19.9, 21.5, 22.0, 23.6, 24.5,25.2, 28.4, 29.5, 31.8±0.2 degrees 2θ.
 48. A process for preparing themodafinil of claim 43 comprising the steps of: a) dissolving modafinilin liquid selected from the group consisting of methylcarbonate, ethanoland dimethylcarbonate mixtures, water and dimethylcarbonate mixtures andacetone and dimethylcarbonate mixtures b) crystallizing modafinil fromthe liquid, and c) separating the liquid to obtain the modafinil ofclaim
 43. 49. A crystalline form of modafinil that produces a powderX-ray diffraction pattern with reflections at 9.3, 18.2, and 20.5±0.2degrees 2θ.
 50. The crystalline modafinil of claim 49 denominatedmodafinil Form VI.
 51. The crystalline form of modafinil of claim 49wherein the reflections at 9.3, 18.2, and 20.5±0.2 degrees 2θ comprise afirst set of reflections of strong intensity and wherein the crystallineform is further characterized by reflections of lesser intensity at 9.0,10.2, 12.4, 15.3, and 20.0±0.2 degrees 2θ.
 52. The crystalline form ofmodafinil of claim 51 that produces a powder X-ray diffraction patternwith reflections at 9.0, 9.3, 10.2, 12.4, 14.2, 14.5, 15.3, 17.5, 18.1,20.0, 20.5, 21.5, 22.0, 23.5, 24.5, 25.0±0.2 degrees 2θ.
 53. A processfor preparing the modafinil of claim 49 comprising the steps of: a)suspending Form V modafinil in a liquid selected from the groupconsisting of water, ethanol and ethanol and water mixtures for a periodof time sufficient to convert the Form V modafinil into the modafinil ofclaim 49, and b) separating the liquid to obtain the modafinil of claim49.
 54. A pharmaceutical composition comprising the modafinil of claim27 and a pharmaceutically acceptable excipient.
 55. A pharmaceuticaldosage form comprising the composition of claim
 54. 56. A pharmaceuticalcomposition comprising the modafinil of claim 33 and a pharmaceuticallyacceptable excipient.
 57. A pharmaceutical dosage form comprising thecomposition of claim
 56. 58. A pharmaceutical composition comprising themodafinil of claim 38 and a pharmaceutically acceptable excipient.
 59. Apharmaceutical dosage form comprising the composition of claim
 58. 60. Apharmaceutical composition comprising the modafinil of claim 49 and apharmaceutically acceptable excipient.
 61. A pharmaceutical dosage formcomprising the composition of claim 60.